System and method for cutting material in continuous fiber reinforced additive manufacturing

ABSTRACT

Methods, apparatus, and systems for cutting material used in fused deposition modeling systems are provided, which comprise a ribbon including one or more perforations. Material is passed through at least one perforation and movement of the ribbon cuts the material. A further embodiment comprises a disk including one or more blade structures, each forming at least one cavity. Material is passed through at least one cavity and a rotational movement of the disk cuts the material. A further embodiment comprises a slider-crank mechanism including a slider coupled to a set of parallel rails of a guide shaft. The slider moves along a length of the rails to cut the material. Yet another embodiment comprises one or more rotatable blade structures coupled to at least one rod. The rotation of the blade structures causes the blade structures to intersect and cut extruded material during each rotation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.14/948,057, entitled: “System and Method for Cutting Material inContinuous Fiber Reinforced Additive Manufacturing”, filed on Nov. 20,2015, and issued as U.S. Pat. No. 10,150,262 on Dec. 11, 2018, which isincorporated herein by reference in its entirety for all purposes.

TECHNICAL FIELD

The present disclosure relates generally to additive manufacturing, andmore specifically to the cutting of materials used in such manufacturingsystems.

DESCRIPTION OF RELATED ART

In many manufacturing processes, materials may need to be shaped throughvarious processes including melting, combining, and/or cutting. Forexample, fused deposition modeling (FDM), also known as fused filamentfabrication (FFF), is an additive manufacturing process commonly usedfor modeling, prototyping, and production application. Suchmanufacturing processes are increasingly being used as a technique for3D printing, modeling, and manufacturing. FDM works on an additiveprinciple by laying down material in layers. A model and/or part istypically produced by extruding small flattened amounts of moltenmaterial and/or support material from an extrusion nozzle to form layersas the material hardens after extrusion from the nozzle.

Typically, the material, such as thermoplastic filament or metal wire issupplied to an extrusion nozzle which can turn the flow on and off.Thermoplastics may be heated past their glass transition temperature toa molten state and are then deposited by an extrusion head.

In some instances, it may be necessary to cut the extruded material atdesired lengths during the additive manufacturing process. For example,if the extruded material is a fiber reinforced feedstock, simply haltingof the fiber reinforced feedstock is insufficient for separating thefeedstock from the extruder. Thus, in such cases, a cutting mechanismdownstream of the extruder or nozzle is required for a clean separationof the feedstock. However, in the additive manufacturing process, themodels and/or parts are assembled quickly in constricted spaces, and itmay be impractical for cutting to be done manually or by typical cuttingdevices. Thus, there is a need for a device and method for cuttingmanufacturing materials in various manufacturing processes that isquick, automated, and not obstructive.

SUMMARY

The following presents a simplified summary of the disclosure in orderto provide a basic understanding of certain embodiments of the presentdisclosure. This summary is not an extensive overview of the disclosureand it does not identify key/critical elements of the present disclosureor delineate the scope of the present disclosure. Its sole purpose is topresent some concepts disclosed herein in a simplified form as a preludeto the more detailed description that is presented later.

In general, certain embodiments of the present disclosure providetechniques or mechanisms for cutting material used in fused depositionmodeling, and in particular for cutting fiber reinforced materials usedin such manufacturing processes. According to various embodiments, afiber reinforced feedstock cutting device is provided which comprises afeedstock pass through zone and a cutting mechanism. A portion of thecutting mechanism defines at least a partial perimeter of the feedstockpass through zone.

In some embodiments, the cutting mechanism comprises a ribbon includingone or more perforations. A feedstock is passed through at least oneperforation of the one or more perforations and movement of the ribboncuts the feedstock. In some embodiments, the cutting mechanism maycomprise one or more sharpened edges outlining each perforation. Infurther embodiments, the one or more perforations may be substantiallyteardrop shaped with respect to one direction. In other embodiments, theone or more perforations may be symmetrically shaped. In someembodiments, the cutting device may further comprise a set of rotatablereels coupled to the ribbon, and rotating at least one of the reelscauses movement of the ribbon in one or more directions. In someembodiments, the cutting device may further comprise one or more motorscoupled to at least one reel, and the one or more motors causes at leastone reel to rotate. In other embodiments the cutting device may furthercomprise one or more guides. The ribbon passes through the one or moreguides and remains within a predetermined space defined by the one ormore guides. In some embodiments, each movement of the ribbon may causeat least one perforation to substantially align with at least oneopening of an extruder in a fused deposition modeling system. In someembodiments, the extruder may include one or more openings. In someembodiments, the feedstock may comprise a continuous carbon fiber orother continuous fiber reinforced composite.

In yet another embodiment, the cutting mechanism comprises a diskincluding one or more blade structures. Each blade structure includes atleast one cavity. A feedstock is passed through at least one cavity anda rotational movement of the disk cuts the feedstock. In someembodiments, the cutting mechanism may include one or more sharpenededges outlining each cavity. In further embodiments, one or morecavities may be substantially teardrop shaped with respect to onedirection. In other embodiments, at least one cavity may comprise atleast one fully enclosed perforation with each blade structure. In someembodiments, the cutting device may further comprise one or more motorscoupled to the disk, and the one or motors causes the disk to rotate. Inother embodiments, each rotational movement of the disk may cause atleast one cavity to substantially align with at least one opening of anextruder in a fused deposition modeling system. In some embodiments, theextruder may include one or more openings. In some embodiments, thefeedstock may comprise a continuous carbon fiber or other continuousfiber reinforced composite.

In yet another embodiment, the cutting mechanism comprises a guide shaftincluding a set of rails positioned in parallel. A feedstock is passedbetween the rails. The cutting device may further comprise a slidercoupled to the rails such that the slider may move along a length of therails from a first position to a second position. The cutting device mayfurther comprise a crank mechanism coupled to the slider, and rotationof the crank mechanism causes the slider to travel the length of therails and cut the feedstock passed between the rails. The slider mayreturn to the first position after each full rotation of the crankmechanism. In some embodiments, the cutting mechanism may include one ormore sharpened edges. In other embodiments, the cutting mechanism mayfurther include an end structure coupled to the guide shaft. In anotherembodiment, the cutting mechanism may comprise a set of blade structuresincluding the one or more sharpened edges. The blade structures arecoupled to the slider, and the end structure is shaped such that the endstructure causes the blade structures to come together and cut thefeedstock when the slider is at the second position. In otherembodiments, the cutting device may further comprise one or more motorscoupled to the crank mechanism, and the one or more motors causes thecrank to rotate. In some embodiments, the guide shaft may besubstantially aligned with at least one opening of an extruder in afused deposition modeling system. In some embodiments, the extruder mayinclude one or more openings. In some embodiments, the feedstock maycomprise a continuous carbon fiber or other continuous fiber reinforcedcomposite.

In yet another embodiment, the cutting mechanism comprises one or moreblade structures, each blade structure including at least one cavity.The cutting mechanism further comprises at least one rod coupled to atleast one blade structure such that the blade structure may rotatearound an axis of the rod. The motion of one or more blade structurescauses the one or more blade structures to intersect with the feedstockpass through zone and cut a feedstock. In some embodiments, the cuttingmechanism comprises a first blade structure coupled to a first rod. Thefirst rod may be arranged opposite to a second rod coupled to a secondblade structure. In other embodiments, the cutting mechanism may includeone or more sharpened edges outlining each cavity. In other embodiments,the one or more cavities may be substantially V-shaped with respect toone direction. In further embodiments, at least one rod may be cantedfrom the feedstock pass through zone such that one or more bladestructures rotates around an axis set at an angle to the feedstock passthrough zone. In another embodiment, the cutting device may furthercomprise one or more motors coupled to the one or more blade structuresand the one or more motors causes the one or more blade structures torotate. In some embodiments, each movement of at least one bladestructure may begin and end with the at least one blade structure in aposition away from at least one opening of an extruder in a fuseddeposition modeling system. In some embodiments, the extruder mayinclude one or more openings. In some embodiments, the feedstock maycomprise a continuous carbon fiber or other continuous fiber reinforcedcomposite.

In yet another embodiment, a method of cutting fiber reinforcedfeedstock is provided which comprises passing a feedstock through afeedstock pass through zone of a cutting device. The cutting deviceincludes a cutting mechanism and at least a partial perimeter of thefeedstock pass through zone is defined by a portion of the cuttingmechanism. The method further comprises moving the cutting mechanismsuch that the cutting mechanism cuts the feedstock. In some embodiments,the cutting mechanism comprises a ribbon including one or moreperforations. Passing the feedstock through the feedstock pass throughzone includes passing the feedstock through at least one perforation. Insuch embodiment, moving the cutting mechanism includes advancing theribbon in one or more directions. In some embodiments, the cuttingmechanism may comprise one or more sharpened edges outlining eachperforation. In further embodiments, the one or more perforations may besubstantially teardrop shaped with respect to one direction. In otherembodiments, the one or more perforations may be symmetrically shaped.In certain embodiments, moving the cutting mechanism may further includerotating a set of reels coupled to the ribbon such that the ribbon isadvanced in one or more directions. In other embodiments, the ribbon maybe advanced through at least one guide and remains within apredetermined space defined by the at least one guide. In a furtherembodiment, one or more motors may be coupled to the set of reels andmay cause at least one reel to rotate. In some embodiments, the methodmay further comprise substantially aligning at least one perforationwith at least one opening of an extruder in a fused deposition modelingsystem after each advance of the ribbon. In some embodiments, thefeedstock may comprise a continuous carbon fiber or other continuousfiber reinforced composite.

In yet another embodiment, a system of cutting fiber reinforcedfeedstock is provided which comprises a source of a feedstock and anextruder configured to extrude the feedstock from one or more openings.In some embodiments, the extruder may include one or more openings. Thesystem may further comprise a cutting device including a cuttingmechanism. A portion of the cutting mechanism defines at least a partialperimeter of the feedstock pass through zone. In some embodiments, thecutting mechanism may comprise a ribbon including one or moreperforations. The feedstock is passed through at least one perforationof the ribbon. The cutting device may further comprise a set of reelscoupled to the ribbon, and rotating the reels causes movement of theribbon in one or more directions. The cutting device may furthercomprise one or more motors coupled to the set of reels, and the one ormore motors causes at least one reel to rotate. The movement of theribbon cuts the material and each movement causes at least oneperforation of the one or more perforations to substantially align withat least one opening of the one or more openings of the extruder. Insome embodiments, the feedstock may comprise a continuous carbon fiberor other continuous fiber reinforced composite.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure may best be understood by reference to the followingdescription taken in conjunction with the accompanying drawings, whichillustrate particular embodiments of the present disclosure.

FIG. 1 illustrates an example of a manufacturing system that can be usedin conjunction with the techniques and mechanisms of the presentdisclosure.

FIG. 2 illustrates one example of a cutting device using a ribbon, inaccordance with one or more embodiments.

FIG. 3 illustrates an alternate view of the example of a cutting deviceusing a ribbon as illustrated in FIG. 2.

FIG. 4 illustrates yet another view of the example of a cutting deviceusing a ribbon as illustrated in FIG. 2.

FIG. 5 illustrates yet another view of the example of a cutting deviceusing a ribbon as illustrated in FIG. 2.

FIG. 6 illustrates an example of a cutting device using a continuousribbon, in accordance with one or more embodiments.

FIG. 7A illustrates an example of a method of cutting material with acutting device in accordance with one or more embodiments.

FIG. 7B illustrates an example of a method of cutting material using aribbon, in accordance with one or more embodiments

FIG. 8A illustrates an example of a cutting device using a disk, inaccordance with one or more embodiments.

FIG. 8B illustrates an alternate view of the example of a cutting deviceusing a disk as shown in FIG. 8A.

FIG. 9 illustrates an example method of cutting material using a disk,in accordance with one or more embodiments.

FIG. 10A illustrates an example of a cutting device using aslider-crank, in accordance with one or more embodiments.

FIG. 10B illustrates an alternate view of the example of a cuttingdevice using a slider-crank as shown in FIG. 10A.

FIG. 10C illustrates yet another view of the example of a cutting deviceusing a slider-crank as shown in FIG. 10A during cutting.

FIG. 11 illustrates an example method of cutting material using aslider-crank in accordance with one or more embodiments.

FIG. 12A illustrates an example of a cutting device using a rotatingblade structure, in accordance with one or more embodiments.

FIG. 12B illustrates an alternate view of the example of a cuttingdevice using a rotating blade structure as shown in FIG. 12A.

FIG. 12C illustrates an alternate view of the example of a cuttingdevice using a rotating blade structure as shown in FIG. 12A.

FIG. 13 illustrates an example method of cutting material using arotating blade structure in accordance with one or more embodiments.

FIG. 14 is a flow diagram of aircraft production and servicemethodology.

FIG. 15 is a block diagram of an aircraft.

DESCRIPTION OF PARTICULAR EMBODIMENTS

Reference will now be made in detail to some specific examples of thepresent disclosure including the best modes contemplated by theinventors for carrying out the present disclosure. Examples of thesespecific embodiments are illustrated in the accompanying drawings. Whilethe present disclosure is described in conjunction with these specificembodiments, it will be understood that it is not intended to limit thepresent disclosure to the described embodiments. On the contrary, it isintended to cover alternatives, modifications, and equivalents as may beincluded within the spirit and scope of the present disclosure asdefined by the appended claims.

For example, the structure and mechanisms of the present disclosure willbe described in the context of particular materials. However, it shouldbe noted that the structure and mechanisms of the present disclosure mayconsist of a variety of different materials. In the followingdescription, numerous specific details are set forth in order to providea thorough understanding of the present disclosure. Particular exampleembodiments of the present disclosure may be implemented without some orall of these specific details. In other instances, well knownstructures, mechanisms, and materials have not been described in detailin order not to unnecessarily obscure the present disclosure.

Definitions

It will be understood that, although the terms “first,” “second.” etc.may be used herein to describe various elements, these elements shouldnot be limited by these terms. These terms are only used to distinguishone element from another. For example, a first contact could be termed asecond contact, and, similarly, a second contact could be termed a firstcontact, without changing the meaning of the description, so long as alloccurrences of the “first contact” are renamed consistently and alloccurrences of the second contact are renamed consistently. The firstcontact and the second contact are both contacts, but they are not thesame contact.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the claims. Asused in the description of the embodiments and the appended claims, thesingular forms “a”, “an” and “the” are intended to include the pluralforms as well, unless the context clearly indicates otherwise. It willalso be understood that the term “and/or” as used herein refers to andencompasses any and all possible combinations of one or more of theassociated listed items. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,elements, components, and/or groups thereof.

As used herein, the term “if” may be construed to mean “when” or “upon”or “in response to determining” or “in accordance with a determination”or “in response to detecting,” that a stated condition precedent istrue, depending on the context. Similarly, the phrase “if it isdetermined [that a stated condition precedent is true]” or “if [a statedcondition precedent is true]” or “when [a stated condition precedent istrue]” may be construed to mean “upon determining” or “in response todetermining” or “in accordance with a determination” or “upon detecting”or “in response to detecting” that the stated condition precedent istrue, depending on the context.

As used herein, the terms “feedstock,” “filament,” and “strand” refer tothinly shaped rods of material of indefinite length with varyingcross-sectional shapes and diameters used generally in fused depositionmodeling and other 3D printing processes, and all such terms may be usedinterchangeably throughout the present disclosure.

Various techniques and mechanisms of the present disclosure willsometimes be described in singular form for clarity. However, it shouldbe noted that some embodiments include multiple iterations of astructure or multiple instantiations of a mechanism unless notedotherwise. For example, a system uses a processor in a variety ofcontexts where mechanisms are controlled automatically, electronically,or wirelessly. However, it will be appreciated that a system can usemultiple processors while remaining within the scope of the presentdisclosure unless otherwise noted. Furthermore, the techniques andmechanisms of the present disclosure will sometimes describe aconnection between two entities. It should be noted that a connectionbetween two entities does not necessarily mean a direct, unimpededconnection, as a variety of other entities may reside between the twoentities. For example, a processor may be connected to memory, but itwill be appreciated that a variety of bridges and controllers may residebetween the processor and memory. Consequently, a connection does notnecessarily mean a direct, unimpeded connection unless otherwise noted.

Overview

According to various embodiments, a fiber reinforced feedstock cuttingdevice is provided which comprises a feedstock pass through zone and acutting mechanism. A portion of the cutting mechanism defines at least apartial perimeter of the feedstock pass through zone. In someembodiments, the cutting mechanism comprises a ribbon including one ormore perforations. A feedstock is passed through at least oneperforation of the one or more perforations and movement of the ribboncuts the feedstock. In some embodiments, the cutting mechanism maycomprise one or more sharpened edges outlining each perforation. Infurther embodiments, the one or more perforations may be substantiallyteardrop shaped with respect to one direction. In other embodiments, theone or more perforations may be symmetrically shaped. In someembodiments, the cutting device may further comprise a set of rotatablereels coupled to the ribbon, and rotating at least one of the reelscauses movement of the ribbon in one or more directions. In someembodiments, the cutting device may further comprise one or more motorscoupled to at least one reel, and the one or more motors causes at leastone reel to rotate. In other embodiments the cutting device may furthercomprise one or more guides. The ribbon passes through the one or moreguides and remains within a predetermined space defined by the one ormore guides. In some embodiments, each movement of the ribbon may causeat least one perforation to substantially align with at least oneopening of an extruder in a fused deposition modeling system. In someembodiments, the extruder may include one or more openings. In someembodiments, the feedstock may comprise a continuous carbon fiber orother continuous fiber reinforced composite.

According to further embodiments, the cutting mechanism comprises a diskincluding one or more blade structures. Each blade structure includes atleast one cavity. A feedstock is passed through at least one cavity anda rotational movement of the disk cuts the feedstock. In someembodiments, the cutting mechanism may include one or more sharpenededges outlining each cavity. In further embodiments, one or morecavities may be substantially teardrop shaped with respect to onedirection. In other embodiments, at least one cavity may comprise atleast one fully enclosed perforation with each blade structure. In someembodiments, the cutting device may further comprise one or more motorscoupled to the disk, and the one or motors causes the disk to rotate. Inother embodiments, each rotational movement of the disk may cause atleast one cavity to substantially align with at least one opening of anextruder in a fused deposition modeling system. In some embodiments, theextruder may include one or more openings. In some embodiments, thefeedstock may comprise a continuous carbon fiber reinforced composite.

According to further embodiments, the cutting mechanism comprises aguide shaft including a set of rails positioned in parallel. A feedstockis passed between the rails. The cutting device may further comprise aslider coupled to the rails such that the slider may move along a lengthof the rails from a first position to a second position. The cuttingdevice may further comprise a crank mechanism coupled to the slider, androtation of the crank mechanism causes the slider to travel the lengthof the rails and cut the feedstock passed between the rails. The slidermay return to the first position after each full rotation of the crankmechanism. In some embodiments, the cutting mechanism may include one ormore sharpened edges. In other embodiments, the cutting mechanism mayfurther include an end structure coupled to the guide shaft. In anotherembodiment, the cutting mechanism may comprise a set of blade structuresincluding the one or more sharpened edges. The blade structures arecoupled to the slider, and the end structure is shaped such that the endstructure causes the blade structures to come together and cut thefeedstock when the slider is at the second position. In otherembodiments, the cutting device may further comprise one or more motorscoupled to the crank mechanism, and the one or more motors causes thecrank to rotate. In some embodiments, the guide shaft may besubstantially aligned with at least one opening of an extruder in afused deposition modeling system. In some embodiments, the extruder mayinclude one or more openings. In some embodiments, the feedstock maycomprise a continuous carbon fiber reinforced composite.

According to further embodiments, the cutting mechanism comprises one ormore blade structures, each blade structure including at least onecavity. The cutting mechanism further comprises at least one rod coupledto at least one blade structure such that the blade structure may rotatearound an axis of the rod. The motion of one or more blade structurescauses the one or more blade structures to intersect with the feedstockpass through zone and cut a feedstock. In some embodiments, the cuttingmechanism comprises a first blade structure coupled to a first rod. Thefirst rod may be arranged opposite to a second rod coupled to a secondblade structure. In other embodiments, the cutting mechanism may includeone or more sharpened edges outlining each cavity. In other embodiments,the one or more cavities may be substantially V-shaped with respect toone direction. In further embodiments, at least one rod may be cantedfrom the feedstock pass through zone such that one or more bladestructures rotates around an axis set at an angle to the feedstock passthrough zone. In another embodiment, the cutting device may furthercomprise one or more motors coupled to the one or more blade structuresand the one or more motors causes the one or more blade structures torotate. In some embodiments, each movement of at least one bladestructure may begin and end with the at least one blade structure in aposition away from at least one opening of an extruder in a fuseddeposition modeling system. In some embodiments, the extruder mayinclude one or more openings. In some embodiments, the feedstock maycomprise a continuous carbon fiber reinforced composite.

DETAILED DESCRIPTION

Thermoplastic and other non-metallic additives typically used asfeedstock in fused deposition modeling systems do not require cutting toseparate extruded strands of the material from the extruder. Suchthermoplastic material may be separated by movement of the extruder awayfrom the extruded strands. Such non-metallic additive manufacturingtechnologies produce unique and complex items, but with limitedmechanical properties and a high coefficient of thermal expansion. Thus,property improvements are necessary to more broadly transitiontechnology for flight hardware from functional prototypes to tooling andend use parts.

One area of particular interest for composite materials in general andfor composite parts formed using additive manufacturing in particular isusing continuous fibers. Continuous fibers provide high strength levelsin the direction of the fiber. For example, a composite feedstock stripformed from a polyaryletherketone (PAEK) resin and filled with 30% byvolume of chopped carbon fibers may have a tensile modulus of about 3million pounds per square inch (MSI). At the same time, a compositefeedstock strip formed from the same resin and filled with 35% by volumeof continuous carbon fibers may have a tensile modulus of greater than10 MSI. Furthermore, composite parts produced using continuous fiberfeedstock are expected to have roughly five times the strength and tentimes the stiffness of comparable unreinforced parts currently produced.Because of their increased strength and other properties, suchcontinuous fiber reinforcements, may require additional cutting afterheating and extrusion to separate the material from the extruder.

According to various embodiments, a cutting device may comprise a thin,flat ribbon structure with multiple perforations. In some embodiments,the perforations may be lined centrally and run along the length of theribbon structure. In some embodiments, the perforations are spacedevenly apart from each other. In some embodiments, material is passedthrough one or more perforations and movement of the ribbon severs thematerial. For example, the material may be continuous fiber or othercontinuous fiber reinforced feedstock used in fused deposition modelingand/or manufacturing. Such material may be a continuous carbonreinforced composite made by continuous compression molding and slitinto feedstock of a desired cross-sectional shape. The material may beextruded through the opening of an extruder aligned with the perforationand may be passed through a perforation of the ribbon. In someembodiments, the material may be extruded through multiple openings ofan extruder. The ribbon may be moved in a predetermined direction sothat the edges of the perforation make contact with the extrudedmaterial. As the ribbon continues movement in the predetermineddirection, the edges of the perforation may slice through the materialuntil the material is completely severed. In some embodiments, theribbon may continue movement in the predetermined direction until asubsequent perforation is aligned with the opening of the extruder.

In some embodiments, the perforations may include sharpened edges tofurther enable the edges to slice through the material. In otherembodiments, the perforations may be “teardrop” shaped with a widerround portion that tapers toward a sharpened point. Material may beextruded and passed through the wider round portion, and as the ribbonmoves in the predetermined direction, the tapered point presses againstthe material to allow for a concentrated cut force for the cutting loadof the continuous fiber extrudate. In other embodiments, theperforations may comprise other shapes such as a triangular, diamond,circular, etc. In further embodiments, the perforations may besymmetrically shaped to allow for cutting by movement of the ribbon inat least two directions.

In certain embodiments, the ribbon may be moved by rotating a set ofreels. In some embodiments, the ribbon may be wound around the set ofreels, and movement of the ribbon is caused by rotating the reels suchthat the ribbon is passed from a first reel to a second reel. In otherembodiments, each reel shaft may be secured to a reel and cause therotation. In some embodiments, the ribbon may be coupled to more thantwo reels. In some embodiments, the reels may contain one or moreprotrusions to form a sprocket structure. In these embodiments, theprotrusions may be shaped and arranged such that the protrusions alignwith the perforations to grip the ribbon and lock the lowest layers ofthe ribbon on each reel in place. In other embodiments, the protrusionsmay align with and grip additional perforations in the ribbon. Othermeans of coupling the ribbon to the reels may be used such as byadhesive, soldering, mechanical attachment, etc.

In other embodiments, a motor may be coupled to each reel and cause therotation of the reels to wind the ribbon. In some embodiments, a motormay be coupled to a reel by a reel shaft which is rotated by the motor.In other embodiments, a motor may be coupled to each reel shaft by aright angle gear drive or other gear arrangement. Various motors may beimplemented in different embodiments, such as a DC motor, a servo motor,a stepper motor, etc.

In further embodiments, the cutting device may include a guide whichkeeps the ribbon's movement contained in a defined space. In someembodiments, the guide may include rails arranged at a distance suchthat the rails stabilize the ribbon and allow the ribbon to passthrough. In some embodiments, the rails formed by the guide mayfacilitate alignment of one or more perforations with a source of thematerial, so that the material may be passed through the one or moreperforations. For example, the center of the guide may include anopening where the opening of an extruder may be positioned such that theribbon's position is forced to pass by the opening of the extruder as itmoves through the rails of the guide. In some embodiments, the openingof the extruder may be flush with the opening of the guide so that a cutmade by the ribbon cuts the material flush with the opening. In otherembodiments, the opening of the extruder may protrude through the guide.

In other embodiments, the perforations may further be aligned by eachsubsequent movement of the ribbon. For example, the guide may keep aperforation of a ribbon aligned with the opening of an extruder suchthat the molten material may be passed through the perforation. Theribbon may then be moved to cut the material as previously describedabove. As the movement severs the material, a subsequent perforation inthe ribbon is moved toward the opening of the extruder and movement ofthe ribbon is stopped when the subsequent perforation is substantiallyaligned with the opening of the extruder so that material may be passedthrough the subsequent perforation.

In yet further embodiments, a cutting device may comprise a thin diskstructure. The thin disk structure may include one or more bladestructures around the circumference of the disk. Each blade structuremay form at least one cavity with sharpened edges outlining each cavity.In some embodiments, material is passed through one or more cavities androtation of the disk causes the sharpened edges of the blade structuresto slice through and cut material within a cavity. For example, thematerial may be continuous carbon fiber reinforced composite used infused deposition modeling and/or manufacturing. The material may beextruded through one or more openings of an extruder aligned with atleast one cavity and may be passed through the each cavity substantiallyperpendicular to the plane of the disk. In some embodiments, thematerial may be extruded through multiple openings of an extruder andpassed through multiple cavities in the disk. In some embodiments, thecavities may be fully enclosed by the blade structure so that thecavities comprise perforations within each blade structure. In otherembodiments, each blade structure may contain multiple cavities and/orperforations. In other embodiments, each blade structure may besymmetrically shaped.

Rotation of the disk may be driven by a drive mechanism that is directedby a controller. Such a drive mechanism may comprise a motor arrangementincluding a DC motor, servo motor, and/or stepper motor. In someembodiments, the drive mechanism may further comprise a transmission andgear arrangement. The rotation of the disk may continue until one ormore subsequent cavities are substantially aligned with one or moreopenings of the extruder so that additional material may be passedthrough the one or more openings.

In yet further embodiments, a cutting device may comprise a slider-crankmechanism including a guide shaft comprising a set of rails positionedin parallel. In some embodiments, material may be passed between therails. For example, the material may be a continuous carbon fiberreinforced composite used in fused deposition modeling and/ormanufacturing. The material may be extruded through one or more openingsof an extruder aligned with the rails.

In some embodiments, a slider is coupled to the set of rails such thatthe slider may move along a length of the rails from a first position toa second position. In some embodiments, a crank mechanism may be coupledto the slider by a connecting rod such that rotation of the crankmechanism causes the connecting rod to push the slider along the lengthof the rails from the first position to the second position and cut thematerial between the rails. The slider returns to the first positionafter each full rotation of the crank mechanism.

In some embodiments, the slider may include one or more sharpened edgesto cut the material. In other embodiments, the slider may include one ormore blade structures. In other embodiments, the rails may be coupled toan end structure of the guide shaft such that material is cut by theforce of the one or more sharpened edges against the end structure. Insome embodiments, the end structure may also include a sharpened edge.In other embodiments, the end structure may include a guide to controlmovement of one or more blade structures coupled to the slider. Infurther embodiments, the slider may be coupled to a set of bladestructures with sharpened edges coupled together at a pivot point on theslider such that the blades may open and close. The set of blades remainopen when the slider is in the first position. The end structure isfurther shaped such that as the slider is pushed along the length of therails toward the second position, the end structure forces the bladestogether to cut the material between the rails. As the slider returns tothe first position, the blades open.

In some embodiments, rotation of the crank mechanism may be driven by adrive mechanism that is directed by a controller with memory and aprocessor. Such a drive mechanism may comprise a motor arrangementincluding a DC motor, servo motor, and/or stepper motor. In someembodiments, the drive mechanism may further comprise a transmission andgear arrangement. In other embodiments, the drive mechanism may comprisea pneumatic cylinder (not shown) connected directly to the slider. Insome embodiments, the crank mechanism may stop rotating after each fullrotation and begin another rotation when another cut is to be made. Inother embodiments, the crank mechanism may make multiple full rotationsfor multiple cuts.

In yet further embodiments, a cutting device may comprise a swivelingblade structure. In some embodiments, the blade structure may be coupledto a pivoting rod such that the blade structure may swivel around anaxis of the pivoting rod. In other embodiments, the blade structure mayrotate around the axis in a full circle. In some embodiments, the bladestructure may include a cavity. In other embodiments, the bladestructure may include a plurality of cavities. In some embodiments, therotation of the blade structure around the axis of the pivoting rodcauses the blade structure to intersect an extruded material and slicethrough and cut material. For example, the material may be a continuouscarbon fiber reinforced composite used in fused deposition modelingand/or manufacturing. The material may be extruded through one or moreopenings of an extruder. The pivoting rod and the blade structure may bearranged such that at one point in the rotation of the blade structure,the cavity substantially aligns with the extruded material and therotational force causes the blade structure to slice through theextruded material at the cavity. The rotational motion of the bladestructure may continue until the blade structure has completely passedthrough and severed the material.

In some embodiments, the cavity may include sharpened edges outliningthe cavity to further enable the blade structure to slice through thematerial. In other embodiments, the cavity may be substantially V-shapedwith a wider portion that tapers toward a sharpened point such that theextruded material enters the cavity at a wider portion. As the bladestructure moves toward the material, the tapered point presses againstthe material to allow for a concentrated cut force for the cutting loadof the material. In other embodiments, the perforations may compriseother shapes such as a triangular, diamond, circular, etc.

In some embodiments, the cutting device may include a plurality of pivotrods coupled to one or more blade structure. For example, the cuttingdevice may comprise two pivot rods with a blade structure coupled toeach pivot rod. In some embodiments, each pivot rod is arranged oppositeto the other in a symmetrical arrangement. The blade structures rotatealong the axis of its respective pivot rod in the same direction(clockwise or counterclockwise) such that the blade structures makecontact with the extruded material simultaneously from oppositedirections. In some embodiments the blade structures may rotate inopposite directions. In other embodiments, the blade structures may notrotate simultaneously or may not make contact with the extruded materialsimultaneously.

In some embodiments, rotation of the blade structures may be driven by adrive mechanism that is directed by a controller with memory and aprocessor. Such a drive mechanism may comprise a motor arrangementincluding a DC motor, servo motor, and/or stepper motor. In someembodiments, the drive mechanism may further comprise a transmission andgear arrangement. In some embodiments, the blade structures may stoprotating after each full rotation and begin another rotation whenanother cut is to be made. In some embodiments, the rotation of theblade structures may begin and end with the blade structures at aposition away from the extruder to limit obstruction of the extruder. Inanother embodiment, the pivot rods may be canted at an angle in relationto the extruder such that the blade structures are furthered positionaway from the extruder at the beginning and end of each rotation aroundthe pivot rods.

Example Embodiments

FIG. 1 illustrates an example of a manufacturing system that can be usedin conjunction with the various techniques and embodiments of thepresent disclosure. According to various embodiments, manufacturingsystem 100 may include controller 102, build chamber 104, roboticmechanism 106, extruder 108, opening 110, opening 110-1, feedstock passthrough zone 111, moveable table 112, object 114, cutting device 116,extruded material 118, material source 120, material feedstock 120-1,material source 121, material feedstock 121-1, material source 122, andmaterial feedstock 122-1. In accordance with various embodiments,manufacturing system 100 may be a fused deposition modeling systemconfigured to build a three dimensional object depicted as object 114.In some embodiments, controller 102 may be a computer system with memoryand one or more processors configured to control various manufacturingprocesses including, but not limited to material input, robotic armmovement, extruder movement, moveable table positioning, and otherprocesses involved in fused deposition modeling. For example, controller102 may be a computer-aided design (CAD) controller and/or acomputer-aided manufacturing (CAM) controller that directs the buildingof object 114 based on a mathematical model of object 114. In someembodiments, the mathematical model of object 114 may be created withcontroller 102 or may be created elsewhere and imported into controller102. In other embodiments, controller 102 may include a list of thedesired structural properties of object 114.

Controller 102 may further include a list of the properties of materialfeedstocks 120-1, 121-1, and 122-1. Material feedstocks 120-1, 121-1,and 122-1 may consist of thermoplastic material comprising milled fiber,chopped fiber, continuous fiber strands, or any combination thereof. Inother embodiments, material feedstocks 120-1, 121-1, and 122-1 mayconsists of other types of thermoplastic or metal material, includingbut not limited to continuous carbon fiber reinforced composite formedby continuous compression molding and slit into feedstock of a desiredcross-sectional shape. In some embodiments, controller 102 may generatea design for object 114 that includes the location and/or geometry ofthe material feedstocks 120-1, 121-1, and 122-1 in object 114.

Build chamber 104 may be an enclosed environment in which object 114 isbuilt. In some embodiments, build chamber 104 may include moveable table112 which comprises a platform (not shown) on which object 114 is built.In some embodiments, moveable table 112 may be configured to rotate theplatform (not shown). In some embodiments, moveable table 112 may bedriven by a drive mechanism that is directed by controller 102, and mayinclude a motor arrangement such as a stepper motor (not shown) and/orservo motor (not shown) coupled to a transmission (not shown) or geararrangement (not shown) for controlled transmission of rotationalmovement of the motor(s) (not shown) to the moveable table 112. In someembodiments, moveable table 112 may be configured to rotate the platform(not shown) in clockwise and counterclockwise directions around the Zaxis under the direction of controller 102. In other embodiments,moveable table 112 may be configured to raise and lower the platform(not shown) in the +Z and the −Z directions under the direction ofcontroller 102. In further embodiments, moveable table 112 may beconfigured to move the platform (not shown) in the +X direction, the −Xdirection, the +Y direction, the −Y direction, or any combinationthereof.

In various embodiments, manufacturing system 100 may further include oneor more robotic mechanisms 106. Robotic mechanisms 106 may be configuredto place opening 110 of extruder 108 at any location in the build volumeof object 114, from various approach angles. In some embodiments,robotic mechanism 106 may be powered by mechanisms such as electricmotors, hydraulic actuators, or combinations thereof, and configured toprovide three or more axes or degrees of freedom. Other embodiments mayinclude any other suitable positioning assembly capable of placingopening 110 at a desired location in the build volume of object 114.Such positioning assemblies may include, but are not limited to, anX-Y-Z rectilinear mechanism, or a delta robot mechanism.

In some embodiments extruder 108 may be configured to melt the materialfeedstocks 120-1, 121-1, and 122-1 and extrude the molten extrudedmaterial 118 via opening 110 through feedstock pass through zone 111. Invarious embodiments, extruder 108 may include one opening 110 ormultiple openings, such as opening 110 and opening 110-1. In someembodiments, feedstock pass through zone 111 may comprise a volume ofspace that may encompass portions of extruder 108, opening 110, andcutting device 116. In some embodiments, at least a partial perimeter offeedstock pass through zone 111 is defined by a portion of a cuttingmechanism of cutting device 116. In various embodiments extruder 108 maydefine an interior chamber for receiving the thermoplastic material. Insome embodiments, extruder 108 may include a liquefier or heatingelement for melting the material feedstocks 120-1, 121-1, and 122-1within the chamber for extrusion through opening 110 and throughfeedstock pass through zone 111 in liquid and/or molten form as extrudedmaterial 118. In other embodiments, extruder 108 may include a motor(not shown) or any other suitable mechanism for pushing the material(not shown) through the chamber (not shown) and out opening 110. In someembodiments, opening 110 may include a needle (not shown) comprising ahollow tube or nozzle (not shown) having a first open end (not shown)that communicates with the chamber (not shown) of the extruder 108 and asecond open end (not shown) that dispenses the molten extruded material118. The dispensing end (not shown) of opening 110 may be circular,oval, square, slotted or any other suitable shape that is capable ofextruding the molten extruded material 118 in a desired cross-sectionalshape. According to various embodiments, one or more motors may be usedfor feeding the material feedstocks 120-1, 121-1, and 122-1 into theextruder 108 from material strand spools 120, 121, and 122. Controller102 may control the rate of the one or more motors, the temperature ofthe heating element, and/or other process parameters previouslydescribed so that the material can be extruded in a manner thatsatisfies the desired structural properties of object 114.

According to various embodiments, extruder 108 may also be configuredwith a cutting device 116 to cut extruded material 118 to theappropriate length after liquefaction and extrusion. In someembodiments, the cutting device may include a blade (not shown) or othersuitable cutting mechanism (not shown) for cutting the one or morestrands of extruded material 118. In various embodiments, a portion ofthis cutting mechanism may define at least partial perimeter offeedstock pass through zone 111. In some embodiments, the cutting device116 may include a cutting mechanism that comprises a ribbon 302 asdescribed in FIGS. 2, 3, 4, 5, and 6. As will be described in FIG. 3 aribbon 302 may be coupled to a set of reels 306 and 307 such thatmaterial is extruded and passed through one or more perforations such asperforations 304-1, 304-2, and 304-3, of the ribbon 302, and movement ofthe ribbon 302 severs extruded material 118 at the desired length. Inother embodiments, cutting device 116 may include a cutting mechanismthat comprises a disk 802 as described in FIGS. 8A and 8B. As will bedescribed in FIG. 8B, disk 802 includes one or more blade structures 804shaped such that each blade structure forms a cavity 806-1 that alignswith opening 110 such that extruded material 118 is extruded through acavity 806-1. Disk 802 may be rotated by one or more motors 808 suchthat blade structures 804 sever extruded material 118 at the desiredlength. In a further embodiment, cutting device 116 may include acutting mechanism as described in FIGS. 10A, 10B, and 10C. As will bedescribed in FIGS. 10A, 10B, and 10C, the cutting mechanism may includecrank mechanism 1002 coupled to guide shaft 1006, slider 1008,connecting rod 1004, and one or more motors 1012. The guide shaft 1006may comprise a set of parallel rails 1006-1 positioned around opening110. The slider 1008 may include one or more sharpened blade structures1009, and positioned to move along a length of the parallel rails 1006-1of guide shaft 1006. As the one or more motors 1012 cause the crankmechanism 1002 to rotate, the connecting rod 1004 may engage the slider1008 to move along a length of the guide shaft 1006 and cut the extrudedmaterial 118. In yet another embodiment, cutting device 116 may includea cutting mechanism that comprises one or more rotatable bladestructures 1206 and 1208 as described in FIGS. 12A, 12B, and 12C. Aswill be described in FIGS. 12A, 12B, and 12C, blade structures 1206 and1208 are coupled to at least one rod 1202 and rotation of bladestructures 1206 and 1208 around an axis Y-1 of rod 1202 causes bladestructures 1206 and 1208 to intersect and cut extruded material 118during each rotation.

In some embodiments, material feedstocks 120-1, 121-1, and 122-1 may becut “upstream” prior to being fed into extruder 108 for heating.However, difficulties and inefficiencies may arise with upstreamcutting. For example, there may be difficulty in predicting the amountof material required for a build sequence. Furthermore, an upstreamcutting process would require reloading of the material feedstocks120-1, 121-1, and 122-1 to feed into the extruder 108 after each cut,which may eliminate an immediate stop/start process and result in lossof calibration with build object 114. Thus, it would be more desirableto print in circuits and limit the number of cuts required in a systemwith upstream cutting. However, limiting the number of upstream cutsresults in a loss of responsiveness and build variety.

Instead. “downstream” cutting of extruded material 118 occurs atfeedstock pass through zone 111, after material feedstocks 120-1, 121-1,and 122-1 are melted and extruded from extruder 108. Downstream cuttingof extruded material 118 may be more desirable because it allows for animmediate stop/start process in real-time which maintains calibrationwith build object 114, allows for a larger variety of components and/orparts to be built, and results in fewer configuration limitations.However, a downstream cutting mechanism may face potential problems withclearance and obstruction with build object 114.

According to various embodiments, techniques and mechanisms aredescribed herein with respect to cutting material in fused depositionmodeling (FDM) manufacturing processes. However, the techniques andmechanisms described are applicable to cutting any type of material invarious manufacturing processes. Furthermore, the techniques andmechanisms described are also applicable to a wide variety of othercontexts. For instance, the techniques and mechanisms described hereinare applicable to any area in which it is desired to quickly and/orautomatically cut material where space is limited.

FIG. 2 is an illustration of an example of a cutting device using aribbon, in accordance with one or more embodiments. According to variousembodiments, cutting device 200 includes ribbon 202, perforations 204,left reel 206, right reel 207, reel shafts 208, gear drives 210, motors212, guide 214, and rails 216. In some embodiments, cutting device 200may be coupled to an extruder 108, as described in FIG. 1.

According to various embodiments, ribbon 202 may comprise a thinstructure which may lie flat on an X-Y plane relative to ribbon 202. Asshown in FIG. 2, the length of ribbon 202 runs in the direction of therelative X axis (marked as XC in FIG. 2) and the width of ribbon 202runs in the direction of the relative Y axis (marked as YC in FIG. 2).As a substantially flat structure, ribbon 202 may have a negligiblethickness in the direction of the relative Z axis (marked as ZC in FIG.2). In other embodiments, the thickness of ribbon 202 may be more thannegligible but not enough to significantly impinge upon the build space.In some embodiments, ribbon 202 may comprise one or more perforations204 lined successively along the center length of ribbon 202 in therelative X axis. In some embodiments, the perforations are spaced evenlyapart. In other embodiments, perforations 204 may be organized invarious arrangements on ribbon 202. In some embodiments, ribbon 202 maycomprise any material or combination of materials that provides thedesired strength, flexibility, durability, hardness, weight, waterresistance, ability to be shaped into a feedstock cutter, or otherdesired physical characteristic.

In certain embodiments ribbon 202 may be coupled to left reel 206 andright reel 207 by being wound around each reel. In some embodiments,left reel 206 and right reel 207 may include one or more protrusions(not shown), such as sprockets and/or claws, arranged such that theprotrusions align (not shown) with perforations 204. In otherembodiments, the protrusions (not shown) may align with other edgeperforations (not shown) along the edge (not shown) of ribbon 202, asfurther described in FIG. 6. The protrusions grip ribbon 202 by passingthrough the perforations to lock in place the lowest layer(s) of thewound ribbon on each reel. In some embodiments, the protrusions mayalign with perforations 204 and grip ribbon 202 by passing through oneor more perforations 204. In other embodiments, ribbon 202 may becoupled to reels 206 and 207 by adhesive, soldering, mechanicalattachment, etc. In some embodiments, each reel 206 and 207 is coupledto a reel shaft 208 upon which each reel 206 and 207 may rotate. Inother embodiments, each reel 206 and 207 is coupled to a reel shaft 208such that each reel shaft 208 rotates each reel.

According to various embodiments, at least one reel 206 or 207 may becoupled to a motor arrangement comprising motor 212 and a gear drive 210for rotational movement of reels 206 and 207. In some embodiments, motor212 may comprise a DC motor, stepper motor, and/or servo motor. In someembodiments, gear drive 210 may comprise a right angle gear drive. Inother embodiments, each reel 206 and 207 may be coupled to a motorarrangement including motor 212 and gear drive 210. In some embodiments,reels 206 and 207 may be rotated clockwise, counterclockwise, or anycombination thereof to move ribbon 202 in a direction in the relative Xaxis of ribbon 202 as ribbon 202 is passed from one reel to the otherreel. As shown in FIG. 2, clockwise rotation of reels 206 and 207 willresult in movement of ribbon 202 in direction A, and counterclockwiserotation of reels 206 and 207 will result in movement of ribbon 202 indirection B.

In various embodiments, cutting device 200 may include guide 214 to keepribbon 202 contained in a defined space as ribbon 202 is moved alongreels 206 and 207. In some embodiments, guide 214 may include a pair ofparallel rail structures 216 arranged at a distance such that the rails216 stabilize ribbon 202 and allow ribbon 202 to pass through withoutshifting in the +Y or −Y directions. In some embodiments rails 216formed by guide 214 may facilitate alignment of one or more perforations204 with an opening of extruder 108, as further described in FIG. 3.

According to various embodiments, at least one perforation 204 isaligned with an opening of extruder 108, such as opening 110, and maydefine at least a partial perimeter of feedstock pass through zone 111,as described in FIG. 1. In certain embodiments, material, such asmaterial feedstocks 120-1, 121-1, and/or 122-1, is extruded fromextruder 108 and through opening 110 and passed through one or moreperforations 204 aligned with opening 108 in a direction substantiallyin the Z axis of ribbon 202 and substantially perpendicular to therelative X-Y plane of ribbon 202. In certain embodiments, as ribbon 202is moved along reels 206 and 207, the edges of perforation 204 slicethrough the material until the material is completely severed, asfurther described in FIG. 3. In some embodiments, perforations 204 mayinclude sharpened edges to sever the material. In further embodiments,the perforations may be “teardrop” shaped with a relatively wider centerportion that is rounded and tapers toward a sharpened point at therelative +X and −X ends, as further described in FIG. 3. As ribbon 202moves along reels 206 and 207, the tapered point of such teardrop shapedperforation 204 presses against the material to allow for a concentratedcut force for the cutting load of the material. In other embodiments,perforations 204 may comprise other geometric shapes such as triangles,diamonds, circles, ovals, etc. In further embodiments, the perforationsmay be symmetrically shaped to allow for cutting by movement of theribbon in a reverse direction in the X axis of the ribbon.

FIG. 3 illustrates an alternate view of the example of a cutting deviceusing a ribbon as illustrated in FIG. 2, in accordance with one or moreembodiments. According to various embodiments, cutting device 300includes ribbon 302, left reel 306, right reel 307, reel shaft 308, geardrive 310, motor 312, guide 314, rails 316, and guide aperture 318.Cutting device 300 also includes perforations 304, including perforation304-1, perforation 304-2, perforation 304-3. In some embodiments,perforations 304 may include one or more sharpened edges 305. In someembodiments, cutting device 300 may be coupled to an extruder 108 withopening 110, as described in FIG. 1.

In certain embodiments, material may be extruded through perforations304 that are substantially aligned with opening 110 of extruder 108. Asshown in FIG. 3, perforation 304-2 is substantially aligned with opening110 and defines at least a partial perimeter of feedstock pass throughzone 111. In some embodiments, guide 314 may also contain a guideaperture 318 through which extruder 108 may extrude material (not shown)through. In some embodiments, a nozzle or needle of opening 110 may lieflush with the guide aperture 318. In other embodiments, a nozzle orneedle of opening 110 may protrude through the guide aperture 318. Incertain embodiments, the parallel rails 316 of guide 314 may stabilizeribbon 302 and allow ribbon 302 to pass through such that guide 314restricts the movement of ribbon 302 in the direction of the YC axis,which is the relative Y axis of ribbon 302, to the space defined byrails 316. By controlling the movement of ribbon 302 in the direction ofthe relative Y axis of ribbon 302, guide 316 ensures alignment of one ormore perforations 304 with opening 110 along the relative Y axis ofribbon 302. Alignment of the perforations 304-1, 304-2, and 304-3 withopening 110 along the relative X axis of ribbon 302 is managed throughmovement of ribbon in the directions A and/or B. This movement may bedriven by one or more drive mechanisms including motor 312 and geardrive 310, and may be directed by a controller, such as controller 102as described in FIG. 1.

In various embodiments, reels 306 and 307 are positioned away fromopening 110 to eliminate obstruction with the build object such asobject 114, as described in FIG. 1. In some embodiments, guide 314brings ribbon 302 to an extended position flush with a nozzle of opening110. In some embodiments, guide 314 may retract to allow a nozzle ofopening 110 to protrude through both the guide aperture 318 andperforation 304-2 while extruding the material through feedstock passthrough zone 111. At the desired length, guide 314 may extend back tobring ribbon 302 back to the extended position flush with the nozzle ofopening 110 before ribbon 302 is moved to cause perforation 304-2 to cutthe material flush with the nozzle of opening 110. Various mechanismsmay be used to retract and extend guide 314, such as a motor mechanismincluding a servo motor (not shown) and/or a stepper motor (not shown).In another embodiment, a dual direction pneumatic air cylinder mechanism(not shown) may retract and extend guide 314. In other embodiments,cutting device 300 may be rotatable around extruder 108 to eliminateand/or reduce obstruction with build object such as object 114. Suchrotation of guide 314 around extruder 108 may be caused by various motormechanisms (not shown) including a servo motor and/or a stepper motor.

As shown in FIG. 3, perforations 304-1, 304-2, and 304-3 may besymmetrical and teardrop shaped including a relatively wider centerportion that is rounded and tapers toward a sharpened point on therelative X axis ends. In some embodiments, the relatively wider centerportion may be large enough for a nozzle of opening 110 to protrudethrough. Perforation 304-2 is substantially aligned with opening 110. Aspreviously described, molten material may be extruded from opening 110and passed through perforation 304-2 in a direction substantially in therelative Z axis of ribbon 302 and substantially perpendicular to therelative X-Y plane of ribbon 202. In some embodiments, material maycontinue to be extruded until at a desired length, at which point,movement of ribbon 302 in directions A or B causes the extruded materialto be cut as tapered edges of perforation 304-2 presses against thematerial. The tapered shape of the edges of perforation 304-2 allow fora more concentrated cut force. In some embodiments, the perforations mayinclude sharpened edges to promote cutting of the material.

For example in FIG. 3, at the desired length, a controller, such ascontroller 102 as described in FIG. 1, may initiate movement of leftreel 306 in a clockwise direction to cause ribbon 302 to move indirection A. In this example, ribbon 302 is passed from right reel 307,which acts as a supply reel, to left reel 306, which acts as a take upreel. In other embodiments, right reel 307 may also rotate clockwise tomove ribbon 302 in direction A. In other embodiments, ribbon 302 may becoupled to left reel 306 and right reel 307 such that left reel 306 andright reel 307 must rotate counterclockwise to move ribbon 302 indirection A. In other embodiments, ribbon 302 may be coupled to leftreel 306 and right reel 307 such that left reel 306 and right reel 307must rotate in opposite directions in order to move ribbon 302 indirection A. As ribbon 302 moves in direction A, the edges at the rightend of perforation 304-2 presses against the material to allow for aconcentrated cut force for the cutting load of the material. Once thematerial has been completely severed, ribbon 302 continues to move indirection A until subsequent perforation 304-1 is substantially alignedwith opening 110 to allow material to be passed through. This processmay be repeated until ribbon 302 is substantially unwound from rightreel 307. Using a subsequent new perforation 304 after each cut ensuresa fresh cut surface with optimal cutting capability for each new cutwithout loss in performance.

In another embodiment, cutting device 300 may be additionally and/oralternatively configured to cut material by movement of ribbon 302 indirection B once ribbon 302 has substantially unwound from right reel307. In other embodiments, cutting device 300 may alternate betweenmoving ribbon 302 in direction A and B based on other instructions orparameters. For example in FIG. 3, at the desired length, a controller,such as controller 102 as described in FIG. 1, may initiate movement ofright reel 307 in a counterclockwise direction to cause ribbon 302 tomove in direction B. In this example, ribbon 302 is passed from leftreel 306, which acts as a supply reel, to right reel 307, which acts asa take up reel. In other embodiments, left reel 306 may also rotatecounterclockwise to move ribbon 302 in direction B. In otherembodiments, ribbon 302 may be coupled to left reel 306 and right reel307 such that left reel 306 and right reel 307 must rotate clockwise tomove ribbon 302 in direction B. In other embodiments, ribbon 302 may becoupled to left reel 306 and right reel 307 such that left reel 306 andright reel 307 must rotate in opposite directions in order to moveribbon 302 in direction B. As ribbon 302 moves in direction B, the edgesat the left end of perforation 304-2 press against the material to allowfor a concentrated cut force for the cutting load of the material. Oncethe material has been completely severed, ribbon 302 continues to movein direction B until subsequent perforation 304-3 is substantiallyaligned with opening 110 to allow material to be passed through. Thisprocess may be repeated until ribbon 302 is substantially unwound fromleft reel 306. By switching the direction of ribbon 302 withsymmetrically shaped perforations 304, cutting device 300 doubles theamount of new, unused cut surfaces for each perforation 304. After eachedge of a perforation 304 has been utilized for a cut, ribbon 302 may bereplaced. However, in some embodiments, a set of sharpened edges in eachperforation 304 may be utilized more than once before replacement.

FIG. 4 and FIG. 5 illustrate further examples of a cutting device usinga ribbon as illustrated in FIG. 2, in accordance with one or moreembodiments. Cutting device 400 may be an alternate view of cuttingdevice 200 and/or 300. According to various embodiments, device 400 mayinclude ribbon 402, left reel 406, right reel 407, motors 412, and guide414. In some embodiments, cutting device 400 may be coupled to anextruder 108 in manufacturing system 100, as described in FIG. 1, orother manufacturing system. In some embodiments, feedstock pass throughzone 111 may comprise a volume of space that may be located at theextruding end of extruder 108. In various embodiments, feedstock passthrough zone 111 may comprise various shapes and volumes depending onthe cutting mechanism. For example, as shown in FIG. 3, a partialperimeter of feedstock pass through zone 111 is at least partiallydefined by perforation 304-2 such that feedstock pass through zone issubstantially teardrop shaped. Alternatively, as shown in FIG. 5, apartial perimeter of feedstock pass through zone 111 is at leastpartially defined by perforation 504 such that feedstock pass throughzone is substantially diamond shaped. Cutting device 500 may be analternate view of cutting device 200, 300, and/or 400. According tovarious embodiments, device 500 may include ribbon 502, perforations504, left reel 506, right reel 507, guide 514, and guide aperture 518.In some embodiments, cutting device 500 may be coupled to an extruder108 with opening 110, as shown in FIG. 1. One or more perforations 504may align with opening 110 and define at least a partial perimeter offeedstock pass through zone 111. As shown in FIG. 5, perforations 504are diamond shaped, however, in other embodiments, perforations 504 maycomprise various other shapes. In other embodiments, cutting device 500may be coupled to a different manufacturing system.

FIG. 6 illustrates an example of a cutting device using a continuousribbon, in accordance with one or more embodiments. According to variousembodiments, cutting device 600 may include ribbon 602, reel 606, reel606-1, reel 607, reel 607-1, motors 612, and guide 614. In someembodiments, cutting device 600 may be coupled to an extruder 108 withopening 110, as shown in FIG. 1. According to various embodiments,ribbon 602 may comprise a continuous band structure. In the embodimentshown in FIG. 6, a ribbon 602 forming a continuous band may comprisemultiple link plates that couple together by joint hinges to form acontinuous track of link plates. Ribbons 602-A and 602-B represent analternate view of various embodiments of ribbon 602. In someembodiments, perforations 604-A may be included within each link plateas shown as ribbon 602-A. In other embodiments, perforations 604-B maybe formed by the shape of two adjacent link plates, as shown as ribbon602-B. Perforations 604-A or 604-B may define at least a partialperimeter of feedstock pass through zone 111 which may comprise a volumeof space located near opening 110. In some embodiments, ribbon 602 maywind around reels 606 and 607. However, in other embodiments the linkplates may form a continuous track of link plates without an end asshown in FIG. 6. In such embodiments, the continuous track of linkplates may instead wrap around an edge of each reel 606 and 607. In someembodiments, cutting device 600 may include additional guides or reels,such as reels 606-1 and 607-1, which act as support reels to controlmovement and/or placement of ribbon 602. In some embodiments, each reel606, 606-1, 607, and 607-1 may be coupled to a motor arrangementincluding motor 612. In some embodiments, each reel 606, 606-1, 607, and607-1 may include one or more protrusions, such as sprockets and/orclaws, as described above to grip and move the track of link plates ofribbon 602. In some embodiments, the protrusions may align withperforations 604 to grip ribbon 602 at the point of contact. In otherembodiments, the protrusions may align with perforations along the edgeof the ribbon, shown as edge perforations 650 in ribbons 602-A and602-B. The protrusions may grip ribbon 602, 602-A, and/or 602-B bypassing through edge perforations 650 and gripping ribbon 602, 602-Aand/or 602-B at the point of contact.

FIG. 7A illustrates an example of a method 700 of cutting material witha cutting device in accordance with one or more embodiments. At 701, afeedstock is passed through a feedstock pass through zone of a cuttingdevice. In some embodiments, the cutting device may include a cuttingmechanism and a portion of the cutting mechanism defines at least apartial perimeter of the feedstock pass through zone. In someembodiments, the feedstock may be extruded material 118 and may comprisea continuous fiber reinforced composite. In some embodiments, thefeedstock may be extruded by extruder 108 through one or more openings,such as opening 110. In some embodiments, the cutting device may becutting device 300 that includes a cutting mechanism, such as ribbon302. In some embodiments, ribbon 302 may include one or moreperforations such as perforation 304-2. In some embodiments, thefeedstock pass through zone may be feedstock pass through zone 111. Aperforation 304-2 that is substantially aligned with an opening, maydefine at least a partial perimeter of the feedstock pass through zone.Alternatively, the cutting device may be one of various embodimentsdescribed in the present disclosure.

At 703, the cutting mechanism, such as ribbon 302, is moved such thatthe cutting mechanism cuts the feedstock, such as extruded material 118.Movement of the cutting mechanism, such as ribbon 302, may be caused byone or more motor arrangements including a motor, such as motor 312, anda gear arrangement, such as gear drive 310. The movement of the motorarrangements may be controlled by a controller, such as controller 102.The movement of the cutting mechanism causes the material to be cut indifferent ways based on the various embodiments in the presentdisclosure.

FIG. 7B illustrates an example of a method 700-1 of cutting materialusing a ribbon, in accordance with one or more embodiments. At 711,material is passed from one or more openings through at least oneperforation in a ribbon. In some embodiments, the ribbon includes one ormore perforations. In some embodiments, the ribbon may be ribbon 302,and the perforations may be perforations 304, which define at least apartial perimeter of a feedstock pass through zone, such as feedstockpass through zone 111, as described in FIG. 3. In some embodiments,passing material, such as extruded material 118, through a perforation,such as perforation 304-2, comprises passing material through afeedstock pass through zone as described in step 701 of method 700. Insome embodiments, the material may be a continuous carbon fiberreinforced composite material extruded from an opening of an extruder ina manufacturing system, such as manufacturing system 100 described inFIG. 1. In some embodiments, the ribbon may include one or moreperforations that are centrally lined along the length of the ribbon. Insome embodiments, the perforations are spaced evenly apart. In otherembodiments, the perforations may be organized in various arrangementson the ribbon. In some embodiments, the material is extruded throughmore than one opening and passed through more than one perforation inthe ribbon simultaneously. In certain embodiments of manufacturingsystem 100, an extruder, such as extruder 108 may include a motor or anyother suitable mechanism for pushing the thermoplastic material througha chamber and out an opening. In some embodiments, the amount and/orrate of material to be extruded and passed through the perforation maybe calculated and determined by a controller, such as controller 102 asdescribed in FIG. 1.

At 713, a direction to move the ribbon is determined. In someembodiments, the ribbon is coupled to a set of reels. In someembodiments, the set of reels may include left reel 206 and right reel207 as shown in FIG. 2. Such determination may be made by a controller,such as controller 102 as described in FIG. 1. For example, as shown inFIG. 2, ribbon 202 may be moved in either direction A or direction B. Invarious embodiments, different parameters may determine which directionto move the ribbon. For example, as shown in FIG. 2, ribbon 202 may bemoved in direction A until ribbon 202 has been substantially unwoundfrom right reel 207. Once, ribbon 202 has been substantially unwoundfrom right reel 207, the controller may determine to move ribbon 202 indirection B so that ribbon 202 is passed from left reel 206 to rightreel 207. In other embodiments, a controller may be programmed toalternate the direction of the ribbon based on various parameters and/orinstructions.

Once the ribbon's direction has been determined, the set of reels isrotated to move the ribbon in the predetermined direction at 715. At715, the set of reels may be rotated such that the ribbon is moved froma first reel to a second reel in a first direction. For example, asshown in FIG. 2, a controller may determine to spin both reels 206 and207 in a clockwise direction in order to move ribbon 202 from right reel207 to left reel 206 in direction A. Alternatively, the set of reels isrotated such that the ribbon is moved from the second reel to the firstreel in a second direction. For example, as shown in FIG. 2, acontroller may determine to rotate both reels 206 and 207 in acounterclockwise direction in order to move ribbon 202 from left reel206 to right reel 207 in direction B. In various embodiments, dependingon how the ribbon is wound around each reel, the controller maydetermine to rotate either reel in a clockwise and/or counterclockwisedirection to cause ribbon to move in a desired direction. The ability tomove the reel in either direction for cutting would provide double thecutting edges in the same length of ribbon as compared to a device withthe ability to move the ribbon in only one direction.

The movement of the ribbon cuts the material by causing one or moreedges of the perforation to press against the material with enough forceto slice through the material. In some embodiments, the perforations mayinclude sharpened edges, which enable greater cutting ability for eachperforation. In further embodiments, the perforations may be “teardrop”shaped with a relatively wider center portion that is rounded and taperstoward a sharpened point, as shown in FIG. 3. For example, as ribbon 302moves along reels 306 and 307, the tapered point of such teardrop shapedperforations 304 presses against the material to allow for aconcentrated cut force on the material. In further embodiments, theperforations may be symmetrically shaped to allow for cutting bymovement of the ribbon in two directions, such as direction A anddirection B as shown in FIGS. 2 and 3.

At 717, the rotation of the reels and movement of the ribbon is stoppedonce a subsequent perforation is substantially aligned with the opening.For example, as shown in FIG. 3, ribbon 302 may be moved in direction Ato sever material passed through perforation 304-2. Ribbon 302 maycontinue moving in direction A until perforation 304-1 is substantiallyaligned with opening 110. Once a subsequent perforation, such asperforation 304-1, is substantially aligned with the opening, additionalmaterial may be passed through the subsequent perforation at 701. Themovement of ribbon 302 may be controlled by a controller such ascontroller 102 as described in FIG. 1. In some embodiments, a controllermay be programmed to move and stop ribbon 302 based on variousparameters and/or instructions. Such parameters and/or instructions mayinclude the distance between each perforation 304. In other embodiments,the controller may detect when a perforation 304 has substantiallyaligned with opening 110 by a sensor mechanism (not shown).

For example, as shown in FIG. 3, once perforation 304-1 is substantiallyaligned with opening 110, additional material may be passed throughperforation 304-1 until it is at a desired length, at which point ribbon302 is moved in either direction A or B to sever the additionalmaterial. Utilizing a subsequent new perforation 304 after each cutensures a fresh cut surface with optimal cutting capability for each newcut without loss in performance.

FIG. 8A illustrates an example of a cutting device 800 using a disk 802,in accordance with one or more embodiments. FIG. 8B illustrates analternate view of the example of a cutting device using a disk as shownin FIG. 8A. According to various embodiments, cutting device 800 mayinclude disk 802, blade structure 804, cavities 806 including cavity806-1, cavity 806-2 and cavity 806-3, sharpened edge 807, and motor 808.In some embodiments, cutting device 800 may be coupled to an extruder108 with opening 110 and feedstock pass through zone 111 located nearopening 110, as shown in FIG. 1. In some embodiments, cutting device 800comprises a relatively flat disk structure 802. As shown in FIG. 8A,disk 802 is flat on an X-Y plane with negligible thickness in thedirection of the Z axis. In other embodiments, the thickness of disk 802may be more than negligible, but not enough to significantly impingeupon the build space. In some embodiments disk 802 comprises multipleblade structures 804 which may be lined around the circumference of disk802. Blade structures 804 are shaped and positioned such that each bladestructure 804 forms a cavity, such as cavity 806-2 (shown in FIG. 8B)which defines at least a partial perimeter of feedstock pass throughzone 111. Material is extruded by extruder 108 through feedstock passthrough zone 111. In some embodiments, one or more openings 110 mayextrude material through at least one cavity 806 substantially alignedwith one or more openings 110. In FIG. 8B, cavity 806-2 is substantiallyaligned with opening 110. In other embodiments, multiple openings 110may be aligned with at least one cavity 806. In some embodiments,material may be passed through the cavity 806-2 in a directionsubstantially in the Z-axis and substantially perpendicular to the X-Yplane.

In various embodiments, each cavity 806 may include sharpened edges 807outlining each cavity. In other embodiments, one or more cavities may besubstantially teardrop shaped, such as cavity 806-3, including arelatively wider portion that tapers toward a sharpened point. In someembodiments, the wider portion may be large enough for a nozzle ofopening 110 to protrude through. Once material has been extruded fromextruder 108 and passed through at least one cavity 806 at a desiredlength, rotation of the disk cuts the material by causing the cavity topress against and slice through the material. A cavity 806 with atapered shape such as a teardrop shape may allow for a more concentratedcut force. In FIG. 8A, disk 802 is rotated clockwise in direction A onthe Z axis. In other embodiments, blade structures 804 may be shapedsymmetrically such that cutting may occur by rotating disk 802 in anopposite counterclockwise direction. In other embodiments, one or morecavities 806 may comprise a fully enclosed perforation within each bladestructure 804, such as cavity 806-3.

According to other embodiments, disk 802 may be coupled to a motorarrangement comprising motor 808 which drives rotational movement ofdisk 802 in direction A. In various embodiments, motor 808 may comprisea DC motor, stepper motor and/or servo motor. Certain embodiments themotor arrangement may include multiple motors. In other embodiments themotor arrangement may include a transmission and gear arrangement.

In some embodiments, blade structures 804 are positioned to be flushwith a nozzle or needle of opening 110. In further embodiments, disk 802may be retractable so that a nozzle of opening 110 may protrude througha cavity 806 that is substantially aligned with opening 110. Forexample, disk 802 in FIG. 8A may retract upwards in the +Z direction.This may limit obstruction of blade structure 804 during extrusion ofmaterial. Once material has been extruded at a desired length, disk 802may extend down the −Z direction such that a blade structure 802 isflush with a nozzle of opening 110 along the Z axis. After suchextension, motor 808 causes rotation of disk 802 to cut the extrudedmaterial. In other embodiments, extruder 108 may retract or extend inrelation to disk 802 to relieve obstruction of opening 110. In furtherembodiments, cutting device 800 may be rotatable around extruder 108 toeliminate and/or reduce obstruction with build object 114.

FIG. 9 illustrates an example method 900 of cutting material using adisk, in accordance with one or more embodiments. At 901, material ispassed from one or more openings through at least one cavity of a diskincluding one or more blade structures. In some embodiments, at leastone cavity is formed by a blade structure. For example, the one or moreopenings may be opening 110 of extruder 108 as shown in FIGS. 1, 8A, and8B. The disk may be disk 802 with cavities 806 formed by bladestructures 804. A cavity 806 substantially aligned with opening 110 maydefine at least a partial perimeter of the feedstock pass through zone,such as feed stock pass through zone 111. In some embodiments, passingmaterial, extruded material 118, through cavity 806 may comprise passingmaterial through a feedstock pass through zone as described in step 701in method 700. In certain embodiments, the blade structures may besymmetrically shaped with one or more cavities on either side. In otherembodiments, the cavities may comprise one or more fully enclosedperforations in each blade structure. In some embodiments, the materialmay be a continuous carbon fiber reinforced composite extruded used in afused deposition modeling system. In certain embodiments, an extruder,such as extruder 108 may include a motor or any other suitable mechanismfor pushing the material through a chamber and out an opening. In someembodiments, the amount and/or rate of material to be extruded andpassed through the perforation may be calculated and determined by acontroller, such as controller 102 as described in FIG. 1.

At 903, the disk is rotated such that movement of the disk cuts thematerial. As shown in FIG. 8B, disk 802 is rotated in direction A to cutthe material passed through cavity 806-2. However, in embodiments wherethe blade structures are symmetrically shaped or where the cavitiescomprise one or more fully enclosed perforation, material may be cut byeither a clockwise or counterclockwise rotation. In some embodimentsrotation of the disk may cause a sharpened edge of a cavity to pressagainst the material and slice the material. In some embodiments, ateardrop shaped cavity may provide a concentrated cut force at thetapered end. Rotation of the disk may be caused by a motor arrangementincluding one or more motors, such as motor 808.

At 905, rotation of the disk is stopped once at least one cavity issubstantially aligned with the one or more openings. For example, asshown in FIG. 8B, disk 802 is rotated in direction A such that thesharpened edges of cavity 806-2 cut the material extruded by opening110. Disk 802 may continue to rate in direction A until cavity 806-1 issubstantially aligned with opening 110. Once a subsequent cavity, suchas cavity 806-1, is substantially aligned with the opening, additionalmaterial may be passed through the subsequent cavity at 901 and so on.The movement of disk 802 may be controlled by a controller such ascontroller 102 as described in FIG. 1. In some embodiments, a controllermay be programmed to move and stop disk 802 based on various parametersand/or instructions. Such parameters and/or instructions may include thedistance between each cavity 806. In other embodiments, the controllermay detect when a cavity has substantially aligned with opening 110 by asensor mechanism (not shown).

FIGS. 10A, 10B and 10C are further illustrations of an example of acutting device using a slider-crank, in accordance with one or moreembodiments. According to various embodiments, cutting device 1000 mayinclude crank mechanism 1002, connecting rod 1004, guide shaft 1006,rails 1006-1, slider 1008, blade structures 1009, sharpened edge 1009-1,end structure 1010, and motor 1012. FIGS. 10A, 10B, and 10C depictalternate views of cutting device 1000. In some embodiments, cuttingdevice 1000 may be coupled to an extruder 108 with opening 110, asdescribed in FIG. 1. In some embodiments, cutting device 1000 maycomprise guide shaft 1006 that includes a set of rails 1006-1 positionedin parallel coupled to slider 1008 such that slider 1008 may move alongthe length of the rails 1006-1 that may be defined by a first positionand a second position. Slider 1008 is coupled to crank mechanism 1002 byconnecting rod 1004 which is coupled to crank mechanism 1002 at a pointaway from the center of crank mechanism 1002. In some embodiments,rotation of crank mechanism causes connecting rod 1004 to move slideralong the length of the rails 1006-1. When slider 1008 is at the firstposition, connecting rod 1004 is parallel to the rails 1006-1 of guideshaft 1006 and slider 1008 is at its closest distance to crank mechanism1002. When slider 1008 is at the second position, connecting rod 1004 isparallel to the rails 1006-1 of guide shaft 1006 and slider 1008 is atits farthest distance from crank mechanism 1002. In some embodiments,slider 1008 travels from the first position to the second position andback to the first position with each full rotation of crank mechanism1002.

In some embodiments, crank mechanism 1002 makes a full rotation toreturn the slider 1008 to the first position after each cut. In someembodiments, the slider will remain in the first position until materialis extruded to a desired length. Once another cut is to be made, crankmechanism 1002 may be rotated again to cause another cut. In otherembodiments, crank mechanism 1002 may make multiple full rotations formultiple cuts before stopping to ensure that material is completely cut.In further embodiments, cuts may be made by partial rotation of crankmechanism 1002 in opposite directions.

In various embodiments, slider 1008 includes one or more sharpened edges1009-1. In some embodiments, material may be extruded out of opening 110and through the parallel rails 1006-1 of guide shaft 1006, which defineat least a partial perimeter of feedstock pass through zone 111. In someembodiments, material may be passed out of multiple openings 110. Ascrank mechanism 1002 rotates, it causes slider 1008 to travel the lengthof the rails 1006-1 and the sharpened edges of slider 1008 cuts theextruded material. In other embodiments, the rails 1006-1 of guide shaft1006 may also be coupled to an end structure 1010. In some embodiments,one or more sharpened edges of slider 1008 may press the extrudedmaterial against end structure 1010 which may further enable thesharpened edges to slice through the extruded material. In someembodiments, end structure 1010 may also include sharpened edges. Inother embodiments, the end structure may be shaped to control movementof one or more blade structures coupled to the slider. For example, asshown in FIGS. 10B and 10C, cutting device 1000 may include a set ofblade structures 1009 coupled to slider 1008 at a pivot point. Endstructure 1010 is shaped with a tapered end such that the set of bladestructures are forced together to cut the material as slider 1008 ispushed into the second position by the crank mechanism. In FIG. 10Bslider 1008 is at a midpoint on guide shaft 1006 and the bladestructures are in an open position. FIG. 10C shows slider 1008 nearingthe second position and closer to end structure 1010. In FIG. 10C, thetapered shape of end structure 1010 forces the blade structures into aclosed position. Once slider 1008 is completely at the second position,in some embodiments, the blade structure may be forced completelyclosed. Other embodiments of cutting device 1000 may include variousother cutting mechanisms. In further embodiments, cutting device 1000may be rotatable around extruder 108 to eliminate and/or reduceobstruction with a build object, such as object 114.

FIG. 11 illustrates an example method 1100 of cutting material using aslider-crank in accordance with one or more embodiments. At 1101,material is passed from one or more openings between a set of railspositioned in parallel to form a guide shaft. In some embodiments, theset of rails may be rails 1006-1 which define at least a partialperimeter of a feedstock pass through zone, such as feed stock passthrough zone 111. In some embodiments, passing material, such asextruded material 118, through the set of rails 1006-1 comprises passingmaterial through a feedstock pass through zone as described in step 701in method 700. A slider is coupled to the rails such that the slider maymove along a length of the rails from a first position to a secondposition. For example, the one or more openings may be opening 110 ofextruder 108 as shown in FIGS. 1, 10B, and 10C. The guide shaft may beguide shaft 1006 with rails 1006-1, and the slider may be slider 1008,as described in FIGS. 10A, 10B, and 10C. In some embodiments, the slidermay include one or more sharpened edges. In other embodiments, theslider may include one or more blade structures. In other embodiments,the rails may also be coupled to an end structure, such as end structure1010 as described in FIGS. 10A, 10B, and 10C. In some embodiments, thematerial may be a continuous carbon fiber reinforced composite extrusionused in a fused deposition modeling system. In certain embodiments, anextruder, such as extruder 108 may include a motor or any other suitablemechanism for pushing the material through a chamber and out an opening.In some embodiments, the amount and/or rate of material to be extrudedand passed through the rails may be calculated and determined by acontroller, such as controller 102 as described in FIG. 1.

At 1103, a crank mechanism coupled to the slider is rotated such thatthe rotation of the crank mechanism causes the slider to travel thelength of the rails and cut the material passed between the rails. Insome embodiments, the crank mechanism may be crank mechanism 1002. Insome embodiments, the crank mechanism may be coupled to the slider by aconnecting rod, such as connecting rod 1004. The connecting rod may becoupled to the crank mechanism at a point away from the center such thatrotation of the crank mechanism causes the connecting rod to engageslider to travel a length of the guide shaft as described in FIGS. 10A,10B, and 10C. In some embodiments, as the slider travels toward thesecond position, the sharpened edges of the slider may cut the materialby slicing through the material.

At 1105, rotation of the crank mechanism is stopped after one fullrotation. As described in FIGS. 10A, 10B, and 10C, the slider may returnto the first position after each full rotation of the crank mechanism.In some embodiments, the slider will remain in the first position untilmaterial is extruded at a desired length at 1101. Once another cut is tobe made, the crank mechanism is rotated at 1103. In other embodiments,the crank mechanism may make multiple full rotations for multiple cutsbefore stopping to ensure that material is completely cut. The movementof the crank mechanism may be controlled by a controller such ascontroller 102 as described in FIG. 1. In some embodiments, a controllersuch as controller 102 may be programmed to move and stop the crankmechanism 1002 based on various parameters and/or instructions. Suchparameters and/or instructions may include a predetermined number ofcuts. In other embodiments, the controller may use a sensor mechanism(not shown) to detect if the material has been completely cut anddetermine if additional cuts are necessary.

FIG. 12A illustrates an example of a cutting device 1200 using arotating blade structure, in accordance with one or more embodiments.FIG. 12B illustrates an alternate view of the example of a cuttingdevice using a rotating blade structure as shown in FIG. 12A. FIG. 12Cillustrates an alternate view of the example of a cutting device using arotating blade structure as shown in FIG. 12A. According to variousembodiments, cutting device 1200 may include rod 1202, rod 1204, bladestructure 1206, cavity 1207, blade structure 1208, cavity 1209,sharpened edge 1209-1, gear drive 1210, gear drive 1211, motor 1212, andmotor 1213. In some embodiments, cutting device 1200 may be coupled toextruder 108 with opening 110, as described in FIG. 1. In someembodiments, extruder 108 extrudes material 1250 through feedstock passthrough zone 111. In some embodiments, material 1250 may comprise acontinuous carbon fiber reinforced composite.

In some embodiments, cutting device 1200 may comprise rod 1202 coupledto blade structure 1206 and rod 1204 coupled to blade structure 1208. Insome embodiments, rods 1202 and 1204 are canted at an angle such thatrod 1202 has an axis of Y-1 and rod 1204 has an axis of Y-2. In someembodiments, blade structures 1206 and 1208 may rotate around an axis ofrods 1202 and 1204 respectively. For example, blade structure 1206rotates on an X-1-Z-1 plane around an axis of rod 1202 in the directionof the Y-1 axis and blade structure 1208 rotates on an X-2-Z-2 planearound an axis of rod 1204 in the direction Y-2 axis. For example, inFIG. 12B, blade structures 1206 and 1208 rotate clockwise in directionA. In some embodiments, feed stock pass through zone 111 may be a volumeof space near opening 110. In other embodiments, at least a partialperimeter of feedstock pass through zone 111 may be defined by the areaencompassed by the rotation of blade structures 1206 and 1208. In someembodiments, each blade structure 1206 and 1208 may include cavities1207 and 1209 respectively. In various embodiments, each cavity 1207 and1209 may include sharpened edges, such as sharpened edge 1209-1,outlining each cavity 1207 and 1209. In other embodiments, one or morecavities 1207 or 1209 may be substantially V-shaped including arelatively wider portion that tapers toward a sharpened point (visiblein cavity 1209 in FIG. 12B).

In some embodiments, the rotation of blade structure 1206 causes cavity1207 to substantially align with extruder 108 such that material 1250extruded from opening 110 is positioned within cavity 1207. Similarly,the rotation of blade structure 1208 causes cavity 1209 to substantiallyalign with extruder 108 such that material 1250 extruded from opening110 is positioned within cavity 1209. In some embodiments, material 1250may be extruded through multiple openings 110 and 110-1, as shown inFIG. 1. In such embodiments, multiple cavities (not shown) may bepositioned to align with multiple extrusions of material 1250.

In some embodiments, the rotational motion of blade structures 1206 and1208 may cause the sharpened edges of cavities 1207 and 1209 to pressagainst the extruded material 1250 and slice through material 1250. Acavity 1209 with a tapered shape such as a V-shape may allow for a moreconcentrated cut force. As previously described, in FIG. 12B, bladestructures 1206 and 1208 rotate clockwise in direction A. In otherembodiments, blade structure 1208 may be shaped symmetrically withcavities arranged such that cutting may occur by rotating bladestructure 1208 in an opposite direction B as shown in FIG. 12B. In someembodiments, blade structures 1206 and 1208 may be coupled to a motorarrangement comprising motors 1212 and 1213, and gear drives 1210 and1211. Such motor arrangement may drive rotational movement of bladestructures 1206 and 1208 in direction A. In various embodiments, motor1212 may comprise a DC motor, stepper motor and/or servo motor. Certainembodiments the motor arrangement may include multiple motors. In someembodiments, gear drives 1210 and 1211 may comprise a right angle geardrive. In other embodiments the motor arrangement may include atransmission and gear arrangement (not shown). In some embodiments,blade structures 1206 and 1208 may be rotated at the same time tosimultaneously make contact with extruded material 1250. In otherembodiments, blade structures 1206 and 1208 may be rotatedindependently. In other embodiments, blade structures 1206 and 1208 maybe rotated in the same or opposite directions.

In some embodiments, blade structure 1206 may be positioned to be flushwith opening 110 or with a nozzle (not shown) or needle (not shown) ofopening 110 when blade structure 1206 is substantially aligned withopening 110. Blade structure 1208 may be positioned to be flush with thebottom of blade structure 1206 when both blade structures 1206 and 1208are substantially aligned with opening 110 and intersecting extrudedmaterial 1250. In other embodiments, both blade structures 1206 and 1208are positioned to be flush with a nozzle or needle of opening 110 whenit is substantially aligned with opening 110. In some embodiments, therotation of each blade structure 1206 and 1208 may begin and end withthe blade structures 1206 and 1208 at a position away from opening 110to eliminate obstruction with a build object, such as object 114described in FIG. 1. With rods 1202 and 1204 canted an angle,obstruction of opening 110 is further minimized when blade structures1206 and 1208 are in a position away from opening 110. In furtherembodiments, cutting device 1200 may be rotatable (not shown) aroundextruder 108 to eliminate and/or reduce obstruction with build object114.

FIG. 13 illustrates an example method of cutting material using arotating blade structure in accordance with one or more embodiments. At1301, material is passed from one or more openings through a feedstockpass through zone of a cutting device, such as in step 701 in method700. In some embodiments, the cutting device may be cutting device 1200with feedstock pass through zone 111. In some embodiments, passingmaterial, such as extruded material 1250, through feedstock pass throughzone 111 comprises passing material through a feedstock pass throughzone as described in step 701 in method 700. For example, the one ormore openings may be opening 110 of extruder 108 as shown in FIGS. 1,12A, 12B, and 12C. In some embodiments, the material may be material1250 as shown in FIG. 12C and may comprise a continuous carbon fiberreinforced composite extrusion used in a fused deposition modelingsystem. In certain embodiments, an extruder, such as extruder 108 mayinclude a motor or any other suitable mechanism for pushing the materialthrough a chamber and out an opening. In some embodiments, the amountand/or rate of material to be extruded and passed through the feedstockpass through zone may be calculated and determined by a controller, suchas controller 102 as described in FIG. 1.

Once material, such as material 1250, has been extruded to a desiredlength, one or more blade structures are rotated around the axis of oneor more rods at 1303. In some embodiments, each rod is coupled to one ormore blade structures. The rotation of the blade structures causes oneor more of the blade structures to intersect with the feedstock passthrough zone and cut the extruded material 1250. In some embodiments theblade structures may be blade structures 1206 and 1208 and the rods maybe rods 1202 and 1204, as described in FIG. 12A. In some embodiments, atleast a partial perimeter of feedstock pass through zone 111 may bedefined by the area encompassed by the rotation of the blade structures1206 and 1208. In some embodiments, the blade structures may includecavities, such as cavities 1207 and 1209, as described in FIG. 12B. Insome embodiments, the cavities may include one or more sharpened edges.In other embodiments, the cavities may be substantially V-shaped withrespect to one direction, such as cavity 1209 in FIG. 12B.

At 1305, rotation of the blade structures is stopped after one fullrotation. In some embodiments, the rotation of the blade structures maybegin and end with the blade structures positioned away from theopening. As described in FIGS. 12A, 12B, and 12C, obstruction of theextruder opening is minimized when the blade structures are positionedaway. In some embodiments, the rods may be canted at an angle, such asrods 1202 and 1204 as described in FIG. 12A to further minimizeobstruction with the extruder opening. In some embodiments, the bladestructures will remain positioned away from the opening until materialis extruded at a desired length at 1301. Once another cut is to be made,the blade structures are rotated at 1303. The rotation of the bladestructures may be controlled by a controller such as controller 102 asdescribed in FIG. 1. In some embodiments, a controller may be programmedto move and stop the blade structures based on various parameters and/orinstructions. Such parameters and/or instructions may include apredetermined degree of rotation. In other embodiments, the controllermay use a sensor mechanism to detect the position of each bladestructure.

Referring more particularly to the drawings, embodiments of thedisclosure may be described in the context of an aircraft manufacturingand service method 1400 as shown in FIG. 14 and an aircraft 1402 asshown in FIG. 15. During pre-production, exemplary method 1400 mayinclude specification and design 1404 of the aircraft 1402 and materialprocurement 1406. During production, component and subassemblymanufacturing 1408 and system integration 1410 of the aircraft 1402takes place. Thereafter, the aircraft 1402 may go through certificationand delivery 1412 to be placed in service 1414. While in service by acustomer, the aircraft 1402 is scheduled for routine maintenance andservice 1416 (which may also include modification, reconfiguration,refurbishment, and so on).

Each of the processes of method 1400 may be performed or carried out bya system integrator, a third party, and/or an operator (e.g., acustomer). For the purposes of this description, a system integrator mayinclude without limitation any number of aircraft manufacturers andmajor-system subcontractors; a third party may include withoutlimitation any number of venders, subcontractors, and suppliers; and anoperator may be an airline, leasing company, military entity, serviceorganization, and so on.

As shown in FIG. 15, the aircraft 1402 produced by exemplary method 1400may include an airframe 1418 with a plurality of systems 1420 and aninterior 1422. Examples of high-level systems 1420 include one or moreof a propulsion system 1424, an electrical system 1426, a hydraulicsystem 1428, and an environmental system 1430. Any number of othersystems may be included. Although an aerospace example is shown, theprinciples of the invention may be applied to other industries, such asthe automotive industry. In some embodiments, the previously describedembodiments of the present disclosure may be implemented in theconstruction of one or more portions of airframe 1418 or interior 1422during component and subassembly manufacturing 1408, system integration1410, or routine maintenance and service 1416.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 1400. Forexample, components or subassemblies corresponding to production process1408 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 1402 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 1408 and 1410, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 1402. Similarly, one or more of apparatus embodiments,method embodiments, or a combination thereof may be utilized while theaircraft 1402 is in service, for example and without limitation, tomaintenance and service 1416.

While the present disclosure has been particularly shown and describedwith reference to specific embodiments thereof, it will be understood bythose skilled in the art that changes in the form and details of thedisclosed embodiments may be made without departing from the spirit orscope of the present disclosure. It is therefore intended that thepresent disclosure be interpreted to include all variations andequivalents that fall within the true spirit and scope of the presentdisclosure. Although many of the components and processes are describedabove in the singular for convenience, it will be appreciated by one ofskill in the art that multiple components and repeated processes canalso be used to practice the techniques of the present disclosure.

1. A fiber reinforced feedstock cutting device comprising: a feedstockpass through zone; and a cutting mechanism, wherein a portion of thecutting mechanism defines at least a partial perimeter of the feedstockpass through zone.
 2. The cutting device of claim 1, wherein the cuttingmechanism comprises: a disk including one or more blade structures,wherein each blade structure includes at least one cavity; wherein afeedstock is passed through at least one cavity and a rotationalmovement of the disk cuts the feedstock.
 3. The cutting device of claim2, wherein the cutting mechanism includes one or more sharpened edgesoutlining each cavity.
 4. The cutting device of claim 2, wherein one ormore cavities is substantially teardrop shaped with respect to onedirection.
 5. The cutting device of claim 2, wherein at least one cavitycomprises at least one fully enclosed perforation within each bladestructure.
 6. The cutting device of claim 2, further comprising one ormore motors coupled to the disk, wherein the one or more motors causesthe disk to rotate.
 7. The cutting device of claim 2, wherein eachrotational movement of the disk causes at least one cavity tosubstantially align with at least one opening of an extruder in a fuseddeposition modeling system, wherein the extruder includes one or moreopenings.
 8. The cutting device of claim 2, wherein the feedstockcomprises a continuous carbon fiber or other continuous fiber reinforcedcomposite.
 9. A system of cutting fiber reinforced feedstock comprising:a source of a feedstock; an extruder configured to extrude the feedstockfrom one or more openings through a feedstock pass through zone, whereinthe extruder includes one or more openings; and a cutting deviceincluding a cutting mechanism, wherein a portion of the cuttingmechanism defines at least a partial perimeter of the feedstock passthrough zone
 10. The system of claim 8, wherein the cutting mechanismcomprises: a disk including one or more blade structures, wherein eachblade structure includes at least one cavity; wherein a feedstock ispassed through at least one cavity and a rotational movement of the diskcuts the feedstock.
 11. The cutting device of claim 10, wherein thecutting mechanism includes one or more sharpened edges outlining eachcavity.
 12. The cutting device of claim 10, wherein one or more cavitiesis substantially teardrop shaped with respect to one direction.
 13. Thecutting device of claim 10, wherein at least one cavity comprises atleast one fully enclosed perforation within each blade structure. 14.The cutting device of claim 10, further comprising one or more motorscoupled to the disk, wherein the one or more motors causes the disk torotate.
 15. The cutting device of claim 10, wherein each rotationalmovement of the disk causes at least one cavity to substantially alignwith at least one opening of an extruder in a fused deposition modelingsystem, wherein the extruder includes one or more openings.
 16. Thecutting device of claim 10, wherein the feedstock comprises a continuouscarbon fiber or other continuous fiber reinforced composite.